This invention is directed to improved ophthalmic and otorhinolaryngological device materials. In particular, this invention relates to soft, high refractive index acrylic device materials that have improved glistening resistance.

BACKGROUND OF THE INVENTION

With the recent advances in small-incision cataract surgery, increased emphasis has been placed on developing soft, foldable materials suitable for use in artificial lenses. In general, these materials fall into one of three categories: hydrogels, silicones, and acrylics.

In general, hydrogel materials have a relatively low refractive index, making them less desirable than other materials because of the thicker lens optic necessary to achieve a given refractive power. Conventional silicone materials generally have a higher refractive index than hydrogels, but tend to unfold explosively after being placed in the eye in a folded position. Explosive unfolding can potentially damage the corneal endothelium and/or rupture the natural lens capsule. Acrylic materials are desirable because they typically have a high refractive index and unfold more slowly or controllably than conventional silicone materials.

U.S. Pat. No. 5,290,892 discloses high refractive index, acrylic materials suitable for use as an intraocular lens (“IOL”) material. These acrylic materials contain, as principal components, two aryl acrylic monomers. The IOLs made of these acrylic materials can be rolled or folded for insertion through small incisions.

U.S. Pat. No. 5,331,073 also discloses soft acrylic IOL materials. These materials contain as principal components, two acrylic monomers which are defined by the properties of their respective homopolymers. The first monomer is defined as one in which its homopolymer has a refractive index of at least about 1.50. The second monomer is defined as one in which its homopolymer has a glass transition temperature less than about 22° C. These IOL materials also contain a cross-linking component. Additionally, these materials may optionally contain a fourth constituent, different from the first three constituents, which is derived from a hydrophilic monomer. These materials preferably have a total of less than about 15% by weight of a hydrophilic component.

U.S. Pat. No. 5,693,095 discloses foldable, high refractive index ophthalmic lens materials containing at least about 90 wt. % of only two principal components: one aryl acrylic hydrophobic monomer and one hydrophilic monomer. The aryl acrylic hydrophobic monomer has the formula

Ar is any aromatic ring which can be unsubstituted or substituted with CH3, C2H5, n-C3H7, iso-C3H7, OCH3, C6H11, Cl, Br, C6H5, or CH2C6H5.
The lens materials described in the '095 Patent preferably have a glass-transition temperature (“Tg”) between about −20 and +25° C.

Flexible intraocular lenses may be folded and inserted through a small incision. In general, a softer material may be deformed to a greater extent so that it can be inserted through an increasingly smaller incision. Soft acrylic or methacrylic materials typically do not have an appropriate combination of strength, flexibility and non-tacky surface properties to permit IOLs to be inserted through an incision as small as that required for silicone IOLs.

Improved soft, foldable acrylic device materials which are particularly suited for use as IOLs, but which are also useful as other ophthalmic or otorhinolaryngological devices, such as contact lenses, keratoprostheses, corneal rings or inlays, otological ventilation tubes and nasal implants, have been discovered. These polymeric materials comprise a functionalized alkyl ethoxylate.

Among other factors, the present invention is based on the finding that use of alkyl ethoxylate monomers in acrylic intraocular lens formulations reduces or eliminates temperature-induced glistening formation in hydrophobic acrylic copolymers. The subject monomers allow synthesis of glistening resistant, low equilibrium water content, high refractive index IOLs.

The device materials of the present invention are copolymers comprising a) a monofunctional acrylate or methacrylate monomer [1], b) a difunctional acrylate or methacrylate cross-linker [2], and c) a functinoalized alkyl ethoxylate [3]. The device materials may contain more than one monomer [1], more than one monomer [2], and more than one monomer [3]. Unless indicated otherwise, references to each ingredient are intended to encompass multiple monomers of the same formula and references to amounts are intended to refer to the total amount of all monomers of each formula.

wherein

B═O(CH2)n, NH(CH2)n, or NCH3(CH2)n;

R1═H, CH3, CH2CH3, or CH2OH;

n=0-12;

A=C6H5 or O(CH2)mC6H5, where the C6H5 group is optionally substituted with —(CH2)nH, —O(CH2)nH, —CH(CH3)2, —C6H5, —OC6H5, —CH2C6H5, F, Cl, Br, or I; and

J=(CH2)a, O(CH2CH2O)b, O, or nothing, provided that if W and W′=nothing, then J≠nothing;

d=0-12;

a=1-12;

b=1-24;

wherein:

n=12, 13, or 14;

e=1-100;

R4═H, CH3, CH2CH3, CH2OH; and

Preferred monomers of formula [1] are those wherein:

B═O(CH2)n;

R1═H or CH3;

n=1-4; and

A=C6H5.
Preferred monomers of formula [2] are those wherein:

R2, R3 independently=H or CH3;

W, W′ independently=O(CH2)d, O(CH2)dC6H4, or nothing;

J=O(CH2CH2O)b or nothing, provided that if W and W′=nothing, then J≠nothing;

d=0-6; and

b=1-10.
Preferred monomers of formula [3] are those wherein:

e=8-50;

R4═H or CH3.
Most preferred monomers of formulas [3] are those wherein

n=13;

e=15-40;

R4═H or CH3.
Representative monomers of formula [3] include:

Monomers of formula [1] are known and can be made by known methods. See, for example, U.S. Pat. Nos. 5,331,073 and 5,290,892. Many monomers of formula [1] are commercially available from a variety of sources. Preferred monomers of formula [1] include benzyl methacrylate; 2-phenylethyl methacrylate; 3-phenylpropyl methacrylate; 4-phenylbutyl methacrylate; 5-phenylpentyl methacrylate; 2-phenoxyethyl methacrylate; 2-(2-phenoxyethoxy)ethyl methacrylate; 2-benzyloxyethyl methacrylate; 2-(2-(benzyloxy)ethoxy)ethyl methacrylate; and 3-benzyloxypropyl methacrylate; and their corresponding acrylates.

Monomers of formula [2] are known and can be made by known methods, and are commercially available. Preferred monomers of formula [2] include ethylene glycol dimethacrylate (“EGDMA”); diethylene glycol dimethacrylate; triethylene glycol dimethacrylate; 1,6-hexanediol dimethacrylate; 1,4-butanediol dimethacrylate; 1,4-benzenedimethanol dimethacrylate; and their corresponding acrylates. Most preferred is 1,4-butanediol diacrylate.

Monomers of formula [3] can be made by known methods. For example, such monomers may be made by esterification reactions involving, for example, the alkyl ethoxylate alcohol and suitable carboxylic acids, acyl halides, or carboxylic acid anhydrides. For example, the alkyl ethoxylate can be heated with a carboxylic acid or carboxylic acid alkyl ester in the presence of a catalyst to form the desired ester, with water or low boiling alcohol as a byproduct which can be removed to drive the reaction to completion. The alkyl ethoxylate can also be treated with an acyl halide in the presence of a base such as triethylamine which serves as a hydrohalide acceptor. The alkyl ethoxylate can also be treated with a carboxylic acid anhydride in the presence of a base such as triethylamine or pyridine which catalyzes the reaction and neutralizes the acid formed.

The copolymeric materials of the present invention contain a total amount of monomer [1] from 75 to 97%, preferably from 80 to 95%, and most preferably from 80-93%. The difunctional cross-linker [2] concentration is generally present in an amount from 0.5-3%, and preferably 1-2%.

The materials of the present invention have at least one monomer [3]. The total amount of monomer [3] depends on the desired physical properties for the device materials. The copolymeric materials of the present invention contain a total of at least 1% and can contain as much as 20% of monomer [3]. Preferably, the copolymeric device materials will contain from 1 to 15% of monomer [3]. Most preferably, the device materials will contain from 1 to 10% of monomer [3].

The copolymeric device material of the present invention optionally contains one or more ingredients selected from the group consisting of a polymerizable UV absorber and a polymerizable colorant. Preferably, the device material of the present invention contains no other ingredients besides the monomers of formulas [1] and [2], the monomer [3], and the optional polymerizable UV absorbers and colorants.

The device material of the present invention optionally contains reactive UV absorbers or reactive colorants. Many reactive UV absorbers are known. A preferred reactive UV absorber is 2-(2′-hydroxy-3′-methallyl-5′-methylphenyl)benzotriazole, commercially available as o-Methallyl Tinuvin P (“oMTP”) from Polysciences, Inc., Warrington, Pa. UV absorbers are typically present in an amount from about 0.1-5%. Suitable reactive blue-light absorbing compounds include those described in U.S. Pat. No. 5,470,932. Blue-light absorbers are typically present in an amount from about 0.01-0.5%. When used to make IOLs, the device materials of the present invention preferably contain both a reactive UV absorber and a reactive colorant.

The device material of the present invention optionally contains reactive UV absorbers or reactive colorants. Many reactive UV absorbers are known. A preferred reactive UV absorber is 2-(2′-hydroxy-3′-methallyl-5′-methylphenyl)benzotriazole, commercially available as o-Methallyl Tinuvin P (“oMTP”) from Polysciences, Inc., Warrington, Pa. UV absorbers are typically present in an amount from about 0.1-5%. Suitable reactive blue-light absorbing compounds include those described in U.S. Pat. No. 5,470,932. Blue-light absorbers are typically present in an amount from about 0.01-0.5%. When used to make IOLs, the device materials of the present invention preferably contain both a reactive UV absorber and a reactive colorant.

In order to form the device material of the present invention, the chosen ingredients [1], [2], and [3], along with any of the optional ingredients, are combined and polymerized using a radical initiator to initiate polymerization by the action of either heat or radiation. The device material is preferably polymerized in de-gassed polypropylene molds under nitrogen or in glass molds.

Suitable polymerization initiators include thermal initiators and photoinitiators. Preferred thermal initiators include peroxy free-radical initiators, such as t-butyl(peroxy-2-ethyl)hexanoate and di-(tert-butylcyclohexyl)peroxydicarbonate (commercially available as Perkadoxe 16 from Akzo Chemicals Inc., Chicago, Ill.). Particularly in cases where the materials of the present invention do not contain a blue-light absorbing chromophore, preferred photoinitiators include benzoylphosphine oxide initiators, such as 2,4,6-trimethyl-benzoyidiphenyl-phosphine oxide, commercially available as Lucirin® TPO from BASF Corporation (Charlotte, N.C.). Initiators are typically present in an amount equal to about 5% or less of the total formulation weight, and more preferably less than 2% of the total formulation. As is customary for purposes of calculating component amounts, the initiator weight is not included in the formulation weight % calculation.

The particular combination of the ingredients described above and the identity and amount of any additional components are determined by the desired properties of the finished device material. In a preferred embodiment, the device materials of the present invention are used to make IOLs having an optic diameter of 5.5 or 6 mm that are designed to be compressed or stretched and inserted through surgical incision sizes of 2 mm or less. For example, the monomer [3] is combined with at least one mono-functional acrylate or methacrylate monomer [1] and a multifunctional acrylate or methacrylate cross-linker [2] and copolymerized using a radical initiator in a suitable lens mold.

The device material preferably has a refractive index in the hydrated state of at least about 1.50, and more preferably at least about 1.53, as measured by an Abbe' refractometer at 589 nm (Na light source) and 25° C. Optics made from materials having a refractive index lower than 1.50 are necessarily thicker than optics of the same power which are made from materials having a higher refractive index. As such, IOL optics made from materials with comparable mechanical properties and a refractive index lower than about 1.50 generally require relatively larger incisions for IOL implantation.

The proportions of the monomers to be included in the copolymers of the present invention should be chosen so that the copolymer has a glass transition temperature (Tg) not greater than about 37° C., which is normal human body temperature. Copolymers having glass transition temperatures higher than 37° C. are not suitable for use in foldable IOLs; such lenses could only be rolled or folded at temperatures above 37° C. and would not unroll or unfold at normal body temperature. It is preferred to use copolymers having a glass transition temperature somewhat below normal body temperature and no greater than normal room temperature, e.g., about 20-25° C., in order that IOLs made of such copolymers can be rolled or folded conveniently at room temperature. Tg is measured by differential scanning calorimetry at 10° C./min., and is determined at the midpoint of the transition of the heat flux curve.

For IOLs and other applications, the materials of the present invention must exhibit sufficient strength to allow devices made of them to be folded or manipulated without fracturing. Thus the copolymers of the present invention will have an elongation of at least 80%, preferably at least 100%, and most preferably between 110 and 200%. This property indicates that lenses made of such materials generally will not crack, tear or split when folded. Elongation of polymer samples is determined on dumbbell shaped tension test specimens with a 20 mm total length, length in the grip area of 4.88 mm, overall width of 2.49 mm, 0.833 mm width of the narrow section, a fillet radius of 8.83 mm, and a thickness of 0.9 mm. Testing is performed on samples at ambient conditions using an Instron Material Tester (Model No. 4442 or equivalent) with a 50 Newton load cell. The grip distance is set at 14 mm and a crosshead speed is set at 500 mm/minute and the sample is pulled until failure. The elongation (strain) is reported as a fraction of the displacement at failure to the original grip distance. Since the materials to be tested are essentially soft elastomers, loading them into the Instron machine tends to make them buckle. To remove the slack in the material sample a pre-load is placed upon the sample. This helps to reduce the slack and provide a more consistent reading. Once the sample is pre-loaded to a desired value (typically 0.03 to 0.05 N) the strain is set to zero and the test begun. The modulus is calculated as the instantaneous slope of the stress-strain curve at 0% strain (“Young's modulus”), 25% strain (“25% modulus”) and 100% strain (“100% modulus).

IOLs made of the ophthalmic device materials of the present invention are more resistant to glistenings than other materials. Glistenings are measured according to the following test. The presence of glistenings is measured by placement of a lens or disk sample into a vial or sealed glass chamber and adding deionized water or a balanced salt solution. The vial or glass chamber is then placed into a water bath preheated to 45° C. Samples are to be maintained in the bath for a minimum of 16 hours and preferably 24±2 hours. The vial or glass chamber is then cooled to ambient temperature for a minimum of 60 minutes and preferably 90±30 minutes. The sample is inspected visually in various on angle or off angle lighting to evaluate clarity. Visualization of glistenings is carried out at ambient temperature with a light microscope using a magnification of 50 to 200×. A sample is judged to have many glistenings if, at 50-200× magnification, there are approximately 50 to 100% as many glistenings as observed in control samples based on 65 weight % PEA, 30 weight % PEMA, 3.2 weight % BDDA, and 1.8 weight % OMTP. Similarly, a sample is judged to have few glistenings if there are approximately 10% or more glistenings relative to the quantity observed in control samples. A sample is judged to have very few glistenings if there are approximately 1% or more glistenings relative to a control sample. A sample is judged to be free of glistenings if the number of glistenings detected in the eyepiece is zero. A sample is judged to be substantially free of glistenings if, at 50-200× magnification, the number of glistenings detected in the eyepiece is less than about 2/mm3. It is often very difficult to detect glistenings, especially at surfaces and edges where more defects and debris have formed, so the sample is rastered throughout the entire volume of the lens, varying the magnification levels (50-200×), the aperture iris diaphragm, and the field conditions (using both bright field and dark field conditions) in an attempt to detect the presence of glistenings.

The copolymers of the present invention preferably have an equilibrium water content (EWC) of 0.5 to 3 weight %. EWC is measured by placing one rectangular 0.9×10×20 mm slab in a 20 ml scintillation vial filled with deionized water and subsequently heating in a 35° C. water bath for a minimum of 20 hours and preferably 48±8 hours. The slab is blotted dry with lens paper and the % water content is calculated as follows:

%watercontent=(wetweight-dryweight)wetweight×100

IOLs constructed of the device materials of the present invention can be of any design capable of being stretched or compressed into a small cross section that can fit through a 2-mm incision. For example, the IOLs can be of what is known as a one-piece or multi-piece design, and comprise optic and haptic components. The optic is that portion which serves as the lens and the haptics are attached to the optic and are like arms that hold the optic in its proper place in the eye. The optic and haptic(s) can be of the same or different material. A multi-piece lens is so called because the optic and the haptic(s) are made separately and then the haptics are attached to the optic. In a single piece lens, the optic and the haptics are formed out of one piece of material. Depending on the material, the haptics are then cut, or lathed, out of the material to produce the IOL.

In addition to IOLs, the materials of the present invention are also suitable for use as other ophthalmic or otorhinolaryngological devices such as contact lenses, keratoprostheses, corneal inlays or rings, otological ventilation tubes and nasal implants.

The invention will be further illustrated by the following examples, which are intended to be illustrative, but not limiting.

The following abbreviations are used throughout the Examples and have the following meanings.

PEA

2-phenylethyl acrylate

PEMA

2-phenylethyl methacrylate

BzA

benzyl acrylate

BzMA

benzyl methacrylate

BDDA

1,4-butanediol diacrylate

AIBN

azobisisobutyronitrile

THF

tetrahydrofuran

AIBN

azobisisobutyronitrile

OMTP

2-(2H-benzo[d][1,2,3]triazol-2-yl)-4-methyl-6-(2-

methylallyl)phenol

TMI

3-isopropenyl-alpha,alpha-dimethylbenzyl isocyanate

MEHQ

methyl hydroquinone or 4-methoxyphenol

Terg15S3-MA

Reacted adduct of Tergitol ™ 15-S-3 alkyl ethoxylate

and methacrylic anhydride

Terg15S7-MA

Reacted adduct of Tergitol ™ 15-S-7 alkyl ethoxylate

and methacrylic anhydride

Terg15S30-MA

Reacted adduct of Tergitol ™ 15-S-30 alkyl ethoxylate

and methacrylic anhydride

Terg15S40-MA

Reacted adduct of Tergitol ™ 15-S-40 alkyl ethoxylate

and methacrylic anhydride

Terg15S3-TMI

Reacted adduct of Tergitol ™ 15-S-3 alkyl ethoxylate

and TMI

Terg15S7-TMI

Reacted adduct of Tergitol ™ 15-S-7 alkyl ethoxylate

and TMI

Terg15S15-TMI

Reacted adduct of Tergitol ™ 15-S-15 alkyl ethoxylate

and TMI

EXAMPLE 1

Terg15S30-MA. 50.1 g (34.0 mmol based on OH#=38.0 mg KOH/g) of Tergitol 15-S-30 surfactant (Dow/Union Carbide), 15.7 g (102 mmol) methacrylic anhydride (Aldrich, 94%), and 20 mg MEHQ (Sigma-Aldrich) were dissolved in 120 g anhydrous pyridine (Burdick & Jackson) in a 500 ml round bottom flask equipped with magnetic stirrer and nitrogen inlet. The reaction mixture was heated at 50° C. for 20 hours, poured into 3000 ml diethyl ether, and subsequently cooled to −20° C. The solvent was decanted and the solid was recovered by centrifugation. The solid was redissolved in ether and the product was recovered as previously described to give 43.8 g (80%) of a white waxy solid.

The reaction components listed in Tables 1-4, except for AIBN, were mixed together with stirring or shaking for at least 30 minutes at 23° C., until all components were dissolved. The AIBN was subsequently added and the reaction mixture was stirred for an additional 5 minutes or longer, until the initiator was dissolved. The reactive components are reported in weight %.

The reactive components were purged for approximately 15 minutes using N2 and placed inside a low humidity N2 purged glove box.

The reactive components were syringed or pipetted onto clean polypropylene mold halves containing 1×10×20 mm rectangular wells and covered with the complementary flat polypropylene mold halves. The mold halves were compressed using binder clips and the mixtures were heat ramped from ambient temperature to 70° C. in 15 minutes, and then cured at 70° C. for 1 hour and 110° C. for 2 hours using a Yamato DKN400 constant temperature oven. The molds were allowed to cool to room temperature. The top mold halves were removed and the rectangular polymer slabs were removed from the wells with tweezers and placed individually in 38×8 mm Histo Plas tissue processing capsules (Bio Plas Inc., San Rafael, Calif.). The slabs were extracted in acetone for a minimum of 8 hours and then air dried at ambient temperature for 20 hours, followed by high vacuum (˜0.1 mm Hg) at ambient temperature for 20 hours, and high vacuum at 70° C. for 20 hours.

The equilibrium water content (EWC) was measured by placing a slab in 20 ml deionized water in a scintillation vial and heating in a 35° C. water bath for a minimum of 20 hours. The slab was blotted dry with lens paper and the % water content was calculated as follows:

The extent of glistening formation was evaluated by equilibrating samples in water at 45° C. followed by cooling to 23° C. and subsequent examination using a light microscope. Samples were first placed in 20 ml scintillation vials containing deionized water and heated at 45° C. for a minimum of 20 hours. The entire cross section (˜200 mm2) of samples was examined for glistening formation approximately 1 to 2 hours after cooling to ambient temperature using an Olympus BX60 microscope equipped with 10× and 20× objectives. The samples were also visually inspected for haze after the ΔT test and all samples remained clear.

The results of Examples 3A through 3X show that the reaction mixture components and their amounts may be varied. All materials were clear and showed low haze.

The refractive index (R.I.) values of Examples 3A through 3F and 3U which contain BzA were higher than 1.55, whereas R.I. values of Examples 3G through 3X, excluding 3U, which contain PEA were slightly lower and between 1.54 and 1.55.

The equilibrium water contents (EWCs) were generally 1% or less when 5 weight percent of the functionalized hydrophilic component was added. The EWC was as high as 2% in Example 3N which contained 8 weight percent of the functionalized hydrophilic component.

In all examples, zero to very few glistenings could be observed per entire slab using 10× or 20× magnification objectives (such that the overall magnification was 50-200×). Glistening sightings were rare and observed mainly along edges.

The materials from Examples 3A through 3X were analyzed to determine their tensile properties. The results are shown in Table 6, below.

The reaction components listed in Table 7 were mixed together and cured as previously described. Higher concentrations of alkyl ethoxylate were used as compared to Tables 1 through 4 due to the relatively lower molecular weight and lower PEG contents of alkyl ethoxylates in Examples 4 through 8. This enables the incorporation of greater amounts of the functionalized alkyl ethoxylates while still maintaining equilibrium water contents of approximately 1.5% or less as shown in Table 8.

The results of Examples 9C through 9G which contain between 3 to 12 weight % of Terg15S15-TMI, as shown in Table 7, show that decreasing the alkyl ethoxylate content below approximately 8 weight % results in the appearance of glistenings and noticeable haze. The results of Examples 9A show that a relatively high incorporation of approximately 15 weight % Terg15S3-TMI, the lowest molecular weight alkyl ethoxylate, results in clear samples but does not eliminate glistening formation.

TABLE 7

Example

(% w/w)

Component

9A

9B

9C

9D

9E

9F

9G

Ex 6

14.7

0

0

0

0

0

0

Ex 7

0

13.2

0

0

0

0

0

Ex 8

0

0

11.8

9.9

7.8

5.7

3.2

PEA

55.3

56.3

57.1

58.5

59.9

61.3

63.0

PEMA

25.5

26.0

26.4

27.0

27.7

28.3

29.1

BDDA

3.0

3.0

3.1

2.9

3.0

3.0

3.1

OMTP

1.5

1.6

1.6

1.6

1.7

1.7

1.7

AIBN

0.43

0.47

0.44

0.45

0.47

0.48

0.51

TABLE 8

Sample

Appearance

Post

Relative

%

Glistening

glistening

Ex. #

R.I.

Extractables

EWC

Test

concentration

9A

1.542

2.7

0.5

clear

many

9B

1.543

2.8

0.7

clear

few

9C

1.546

6.1

0.9

clear

0

9D

1.545

5.4

0.8

clear

0

9E

1.550

4.0

0.6

slightly hazy

—

9F

1.549

4.1

0.6

slightly hazy

many

9G

1.551

2.5

0.9

slightly hazy

many

This invention has been described by reference to certain preferred embodiments; however, it should be understood that it may be embodied in other specific forms or variations thereof without departing from its special or essential characteristics. The embodiments described above are therefore considered to be illustrative in all respects and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description.